22.11.2021

Gearbox dsg - automatic transmission repair dsg Volkswagen, Skoda, replacement of mechatronics, clutch. Which box is better automatic transmission or dsg What is a dsg box

What is DSG? The German abbreviation DSG stands for Direct Engagement Gearbox (Direkt Schalt Getriebe). Often it is called "preselective", that is, able to keep ready gears for the next shift.

The idea of creating such a checkpoint belongs to the French inventor Adolf Kegress. In the 30s of the last century, an automotive engineer collaborated with Citroen. He proposed to put a unit with two clutches and hydromechanical control on the front-wheel drive Citroen Traction Avant. The new transmission was not widely used due to its complex design.

The technical consultant of Volkswagen Favorit Hoff Maxim Ponomarenko spoke about the advantages and features of the box.

How the DSG works

The fundamental difference between a preselective automatic transmission and others is in two clutches that quickly change gears. In a “mechanics” or robotic gear change, the clutch disc is disconnected from the flywheel, the driver or robotic computer selects the desired “speed”, and after that the disc snaps into place. During this time, the torque is not transmitted to the box and the car loses its dynamics.

The DSG system eliminates power dips. At the heart of the box is the work of two shafts located coaxially: the first is hollow, and the second is inside it. The engine is connected to each of them through its own, separate multi-plate clutch - also external and internal. On the primary, that is, the outer shaft, gears of even gears (2-, 4-, 6th) are fixed, on the inner - odd - 1-, 3-, 5th and reverse gear.

When the car starts, the odd-numbered disk is pressed against the rotating flywheel, and the even-numbered "speeds" disk is open. During acceleration, the computing unit of the box gives the command to prepare the second gear, so that at the moment it is turned on, disconnect the disk of the odd row and immediately put the even disk into operation. Tuned shift control ensures no loss of torque.

The DSG 6 robotic gearbox entered the Volkswagen conveyor in 2003. The double clutch on it worked in an oil bath, being called "wet". Oil in such a box takes away part of the power, increasing fuel consumption. In 2008, the German automaker introduced a seven-speed DSG 7 with a dry clutch.

Advantages of DSG

The DSG box, due to the optimal modes of switching on the necessary “speeds”, reduces fuel consumption. Cars with it consume about 10% less fuel than cars with a conventional gearbox.
A distinctive feature of all such transmissions is dynamic acceleration. To shift gear up, the box needs only 8 ms, it does not have the effect of rubber traction as on hydromechanical automatic transmissions.
You can drive the DSG in manual mode, that is, shift gears manually.
Such an automatic transmission is 20% lighter than a similar hydromechanical transmission.

Disadvantages of DSG

The cost of an automatic transmission affects the price of a car, significantly increasing it.
Expensive oil change (on a six-speed box) every 60 thousand kilometers. The total volume is 6.5 liters.

The preselective box is mounted on different models and brands united under the name of the Volkswagen concern: Audi TT (A1, A3, A4, S4, A5, A7, A6, Q5, R8), SEAT Ibiza (León, Altea), Škoda Octavia (Superb, Yeti), Volkswagen Polo ( Golf, Jetta, Touran, New Beetle, Passat, Passat CC, Sharan, Scirocco, Caddy).

Extended DSG Warranty

Among many car owners, the dubious fame of a box with two clutches has entrenched. The very name DSG has become a symbol of an unreliable design with costly repairs. In fact, Volkswagen has long taken control of the situation. An important step towards quality control is a large-scale service campaign.

The concern gives an extended warranty for seven-speed gearboxes manufactured before January 1, 2014. According to representatives of the automaker, the designated period corresponds to the appearance on the conveyor of a modernized transmission without typical problems the past generation. Special service conditions are limited to 150,000 miles or 5 years of age of the movement. Service includes replacement synthetic oil mineral - less aggressive towards electronic components. At the same time, the firmware of the automatic transmission control unit is updated. Detected malfunctions are eliminated free of charge - this applies to repair, replacement of individual elements or transmission as an assembly.

In any case, the abbreviations DSG should not be afraid: with the proper level of service, it will not let you down, and in terms of the number of advantages, the “smart robot” outperforms the classic automatic transmission. And the DSG box will require less money for repairs compared to the usual "automatic".

What malfunctions are typical for DSG?

The most common problem is jolts when changing gear that accompanies movement. The clutch discs close too sharply and the car jerks. The second known drawback is vibration at start-up, clanging, grinding and other extraneous noises during gear changes.

The main reason for the incorrect operation of the seven-speed transmission is its "dry" clutch. It wears out quickly due to harsh operating conditions in dense city traffic, with congestion at low speeds. Therefore, the question "how to operate the DSG?" there is one obvious answer - to avoid the "gas-brake" mode, because the main enemy of the robot is the cork.

Among other problems: wear on the shaft bushings, clutch release forks, broken solenoid contacts, dirt on the sensors and oil in antifreeze.

How to determine a DSG malfunction when buying a used car?

Individual gears do not turn on - the box "jumps" them.
Gear shifting is accompanied by shocks - the box "kicks".
There is a hum when driving.
The car vibrates on start up.
Inspection on the lift shows that oil is leaking from the box.

If there is a suspicion of incorrect operation of the box, it is worth ordering an additional check, or postponing this option.

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The automotive industry is developing at an accelerated pace. Every year there are more and more new technologies. Some 20 years ago, automatic transmission was a curiosity for many Russian motorists. Today, the list of available transmissions has expanded. If speak about German cars, then they can often be found with DSG 7. Reviews about it, the device and features of this transmission - later in our article.

Characteristic

So what is this box? It is a robotic transmission manufactured by the Volkswagen-Audi concern. Initially, this box was supposed to have six speeds. However, three years later, a 7-speed DSG box was born. Reviews of the owners about it were also contradictory. Many complained about frequent problems (we will look at them a little later). The main goal of creation is to get a box that would provide gear shifting without interrupting the power flow. This is a key feature of the DSG, which distinguishes it from other robotic gearboxes. At the same time, a car with DSG has better acceleration dynamics and lower fuel consumption.

To ensure continuous transmission of torque from the internal combustion engine to the wheels, German engineers used two clutches and two rows of gears. If speak about technical specifications, DSG 7 is designed for torque up to 250 Nm. The working pressure of the hydraulic accumulator is from 50 to 75 bar. The volume of refillable oil is 1.7 liters.

Device

The box design includes:

Main gear.
Dual mass flywheel.
Double clutch.
Two rows of gears.
Differential.
Control system.

Principle of operation

The clutch drive disc, which rotates the engine, is located between two driven discs that are connected to the box. One of them is connected to the gears and the shaft of an odd number of gears (first, third, fifth, seventh), and the second is connected to the shaft of even ones (respectively, the second, fourth and sixth). When the machine starts moving, only the odd numbered disk is pressed against the drive disk. So the car starts in first gear. With an increase in speed, an odd row is disconnected from the leading disk and an even row is instantly attached. When the last one works, the third gear will already be selected on the odd one. Due to this, the switching occurs instantly. That is, the principle of operation is to sequentially turn on the gears of both rows.

Where is it applied?

Since the seven-speed gearbox can withstand a small amount of torque, it is used on B and C-class cars, as well as on some D-segment cars. More specifically, such a transmission is used on cars:

Volkswagen.
"Seat".
"Skoda".

Basically, these are cars with a small engine size - up to 1.8 liters. On more productive engines, a “wet” six-speed DSG is installed.

DSG 7 malfunctions and reviews

Now let's look at the problems associated with this. One of the common faults concerns the gear shift fork. This element moves by means of a ball bushing-bearing. It does not withstand the loads placed on it, since the switching occurs quickly and harshly. If the sleeve is damaged, its inner plate begins to float in the box. This causes gear damage. Due to metal debris, the Hall sensor is clogged, thanks to which the mechatronic control system operates. Due to the destruction, balls can also fall out. Sometimes the box grinds them too. It is no longer recoverable.

The DSG 7 design has two forks. Many people believe that only the first and second gear forks can break. But the sixth and rear fork fails no less often. The bearing design is identical here. After 2013, German engineers revised the structure of these elements. On the new boxes, the bushings have become solid, without a ball bearing. What do the reviews say about the DSG 7 Volkswagen? With the new bushing, the box has become really more reliable. But buying used cars before 2013 is still dangerous.

Otherwise, mechanical failures are associated with oil contamination due to broken rods. It is necessary to monitor the purity of the liquid. otherwise, the metal dust contained in the oil can cause:

Gear chipping.
Breakage of the differential (at increased load, satellites are welded to the axle).
Overheating of bearings and complete destruction of the seventh gear.

Other problems occur due to insufficient oil levels or due to improper assembly (or transmission tuning) after it has been repaired.

Clutch

Almost every owner has experienced this problem. According to the reviews of the owners, the 7-speed DSG box has flywheel wear. It wears out due to torsional vibrations during slippage and sharp starts. Also, reviews of the DSG 7 box say that the transmission does not like overheating. The clutch block must be clean.

The slightest dirt is negatively displayed on the quality of the DSG 7 on the Volkswagen Passat. Reviews note that the cost of replacing the clutch assembly is very high. The price of this operation is from 50 to 80 thousand rubles, which is comparable to overhaul any machine. And this despite the fact that the clutch has a small resource. According to reviews, DSG 7 Skoda should be serviced every 50 thousand kilometers. In 2012, engineers installed a shield on the hole for the release rods. This made it possible to reduce crankcase contamination and clutch wear. Also note that the transmission needs to adjust the working clearance of the discs. According to reviews, Skoda-Octavia with DSG 7 should be tuned and serviced only in a specialized service. You should not do any work yourself.

Very often, the resource is reduced due to the movement of the car in traffic jams and over rough terrain. But as the reviews say, the Skoda DSG 7 box does not need to be switched to neutral. Both disks rotate freely from each other. Therefore, by transferring the selector to neutral, you do not reduce the load on the clutch assembly and on the mechatronics.

About the resource

According to the reviews of the owners, DSG 7 has a short service life. The resource is about 150 thousand kilometers. Further with the box, even bigger problems begin. By the way, even on the new DSG 7, owner reviews noticed problems. The box twitches and selects the wrong rpm for shifting gears.

Mechatronics breakdowns

We continue to study reviews of the DSG 7. This transmission also has malfunctions regarding the electro-hydraulic control unit. Moreover, these breakdowns can also affect the mechanical part. As noted by the reviews, DSG 7 has the following malfunctions. It:

Failure of the electronic board or its sensors.
Failure of the pressure accumulator.
Failure of the pump motor and control solenoids.
Problems with the mechatronics housing or the accumulator glass. Owners are faced with such a phenomenon as channel cracks.
Loss of tightness of the box and various leaks.

Many had to completely replace the mechatronics of the robotic transmission due to the complexity of the design and the lack of spare parts. The situation worsened in 2015. So, the mechatronics began to be flashed and when installed on another machine, it simply did not work. In view of this, it was impossible to purchase any block from disassembly. I had to shell out for a new one.

Electrical faults

Among the most insignificant reviews are blown fuses in the power circuit. Also on the DSG, the conductors of the board burn out, damaging its case. Due to breakdowns with the pump, the car simply refuses to go further. Another problem is a burnt pump winding. The board is ceramic and is very afraid of temperature changes, vibrations and overheating. However, this unit is still amenable to repair. But this requires special equipment.

How to save a resource?

Do not make slippage at start.
In the event of a long stop, the neutral mode should be switched on.
It is not recommended to quickly move through the rows at speeds up to 50 kilometers per hour.
Time to change transmission oil(every 40 thousand kilometers).

Summing up

So, we found out what a robotic seven-speed DSG box is. Among its positive points it is worth noting:

The speed of switching speeds. Transmissions are switched on almost instantly and even faster than on a manual transmission.
High accelerating dynamics. This is achieved by continuously supplying torque to the wheels of the car.
uniform acceleration. In the case of conventional mechanics or an automatic transmission, characteristic jerks are observed during dynamic acceleration and an attempt to change gear.
Ability to work in manual mode. This function allows the driver to independently choose the style of movement.

But there are a number of disadvantages, due to which many motorists refuse to purchase a car on a DSG, in favor of a conventional automatic machine or mechanics:

Small resource. Even with proper maintenance, such a box runs an average of 150 thousand kilometers.
Unreliability. Common breakdowns that occur with a robotic seven-speed DSG box, we listed earlier.
Low liquidity in the market. Many people know about DSG malfunctions, and therefore it will be difficult to sell such a car.
The complexity of the repair. It is not possible to carry out any repairs yourself. This work requires specialized equipment, knowledge and tools.
Complicated and expensive, a special oil is used, which is more expensive than the usual "transmission". Also, replacement can only be done in the service. And this is an additional cost.
The high cost of the car. Cars with DSG are much more expensive than with a conventional machine.

Is it worth it to buy a car with a seven-speed robotic box? There is no single answer to this question. Experts note that it is advisable to take such a car if it is new and under warranty. Then you can really appreciate the benefits of using DSG without any investment. But if you settle for second-hand german auto, you should refuse to buy a car with DSG. The warranty for this box is in most cases overdue and the future owner will have to deal with malfunctions on their own. And since the box is very complex, you need to look for specialized services. This significantly affects the cost of maintaining a car. The cost of repairing the box turns out to be unreasonably high. Therefore, in the secondary market, preference should be given to mechanics or a classic six-speed automatic.

DSG is a modern robotic automatic transmission, which is actively used on cars of the large Volkswagen concern. It is also called a preselective gearbox. Today we will figure out why the DSG 7 box is better than the more familiar “automatic”, how reliable it is and whether it is worth taking a car equipped with it.

Varieties of DSG boxes

In order to make the driving process more comfortable and safe, automobile concerns constantly offer some new developments, improving the systems of their cars. At the time, when automatic box transmission, there has been a real breakthrough in this area. Years have passed and today there are even newer and more advanced systems. We are talking, first of all, about the DSG 7 box from Volkswagen, which, in comparison with a conventional automatic transmission and a conventional manual gearbox, has a number of undeniable advantages:

There is no loss of engine power during gear changes with DSG. This allows you to achieve maximum acceleration dynamics and save on fuel well - your car will consume 10-15 percent less gasoline;
DSG 7 supports shifting between automatic and manual transmissions, allowing the driver to choose the level of driving comfort.

These are the two main advantages of the DSG 2015, but they are what made this gearbox a real hit, both at the time of its introduction and today. By the way, more than a million of such gearboxes have already been produced, and Volkswagen is not going to stop.

How does a DSG gearbox work?

The principle of operation is quite simple, if you understand. During the start of the movement, the DSG includes two gears at once - first and second - however, in the second, the clutch remains open. When it's time to change gear, the first clutch opens and the second closes at the same time. We can say that the whole work of the DSG 7 gearbox and its analogues is built on this cycle.

It is worth explaining why the DSG is often called a robotic gearbox. The thing is that when shifting gears, not hydromechanics is used, but hydraulics, which is controlled by a special Mechatronics unit. This is a whole group of hydraulic and electronic elements that are connected to a variety of sensors necessary for the correct and efficient operation of the DSG 7 box on a Volkswagen. The unit constantly receives the necessary data from the sensors, on the basis of which one or another programmed algorithm is activated that controls the correct and timely gear shifting.

What types of DSG gearboxes are there?

Of course, the most popular DSG box model is the seventh. However, two types are common, DSG 6 and DSG 7, which are actively put on various cars of the Volkswagen concern. The sixth model appeared back in 2003, and the seventh, three years later.

home DSG feature 6 - the presence of an oil bath, in which disk packs continuously operate. In the same place, they simultaneously lubricate and cool. Thus, using the sixth box model, you get excellent grip. However, the main advantage of the "six" was the limitation of the engine size in which it can be used. The range is quite wide - from 1.4 liters to 3.2 liters - but such a heavy gearbox (almost 95 kilograms) simply did not fit into budget cars, which Volkswagen produces much more. So in 2006, the second type of such a gearbox appeared - DSG 7.

The main difference between the "seven" and its predecessors is a dry clutch. Moreover, it was developed exclusively for use in cars with low-power engines that are not physically capable of delivering more than two hundred and fifty newtons of torque. So, the oil in the DSG 7 box does not need to be poured so often, and it requires almost three times less than for the DSG 6. The weight of the box is only seventy kilograms, and it “spends” seven percent less fuel than its counterparts.

DSG 7 box: Problems and cons

The DSG 7 box is considered quite reliable and efficient, as evidenced by driver reviews that have accumulated over nine years. But, problems and various shortcomings still pop up from time to time. More on the most common DSG problems 7 and how to deal with them.

To start, here is a list of the main disadvantages of a car with a DSG box:

You will have to shell out more money, since a car equipped with a DSG gearbox is much more expensive than one equipped with conventional mechanics or even an automatic one;
Repair of such a gearbox is very time-consuming and expensive;
The service life, even under the most favorable conditions, is significantly less than the usual six-speed gearbox;
Mechatronics often act up due to temperature changes (especially the problem is obvious in winter);
Mechatronics, broken down, can no longer be repaired. It will have to be changed completely, again, having laid out a tidy sum from the wallet;
Oil changes are three times more expensive than usual;
Sometimes there is a jerking effect during the transition from first gear to second;
The preselector works continuously, which means that the problem of warming up, if it does not appear from the very beginning, will soon begin to bother the car owner.

In principle, above we have outlined almost all the significant shortcomings of the DSG 7 box. Many believe that they greatly affect the reputation of the system and greatly spoil the driving experience. However, to be completely honest, all these problems are quite rare, moreover, any system wears out sooner or later and requires increased attention. For example, conventional mechanics can also quickly erase the clutch, which is not a cheap pleasure to replace. So, even taking into account all the shortcomings, we cannot say that the DSG 7 gearbox from Volkswagen is a bad system.

How to use the DSG 7 correctly

In fact, despite the interest of many car enthusiasts in how to properly use the DSG box so that it lasts longer, there is no exact answer. The only thing the driver can do to improve the efficiency of the gearbox is to use the selector to set the correct and efficient mode on his own, suitable in all respects for the style of driving the car.

It is equally important to constantly monitor the operation of the DSG 7 gearbox on a Volkswagen. It should always run quickly and very smoothly. As soon as some unusual twitches or suspicious noises appear, the first thing to do is to go to the service, since such behavior is not typical of a working box.

Relatively recently, manufacturers began to actively install robotic gearboxes on cars instead of the usual and. As you know, a robot (manual transmission) is a mechanical transmission in which automatic on / off is implemented, and the desired gear is selected and switched on without the participation of the driver.

In other words, the box-robot is another type of automated transmission, while it is cheaper to manufacture, simpler in design, provides high fuel efficiency.

Read in this article

Robotic gearbox DSG (DSG): what is it

So, in order to understand what DSG is, one must first consider the main types of robotic boxes. In a nutshell, a robotic gearbox can be either a “single-disk” robot (for example), or a dual-clutch preselective robotic gearbox.

An ordinary robot, which has only one clutch, is similar in design to, while the clutch on / off and the gears are controlled by automation (using electric and hydraulic servos under the control of the ECU box).

This design is simple, the gearbox itself is quite reliable, however, when shifting gears, there is a certain discomfort, the car “nods” during intensive acceleration, a single-disk robot often delays the inclusion of downshifts and upshifts, etc. Also, during operation, the clutch itself wears out quickly.

DSG box: device and principle of operation

In turn, DSG (Direct Shift Gearbox) is a direct shift gearbox developed by Volkswagen. Simply put, it's still the same mechanical box, but there are already two clutches.

Moreover, in such a box two manual gearboxes are combined in one housing at once. Each of these conditional boxes has its own clutch disc. In this case, one box is responsible only for even gears, while the other for odd ones.

To shift up or down a step, the driver (in the case of a manual transmission) or the ECU (in the case of a single-disk robot) disconnects the clutch disc from the flywheel, then engages a gear, and then reconnects the clutch disc. At the same time, it is not transmitted to the wheels until the clutch disc is connected to, the car noticeably loses its dynamics, and fuel consumption increases.

If we talk about DSG, for example, when a car with such a gearbox accelerates, an odd-numbered clutch is attached to the rotating flywheel, while the even-numbered disk is in the open form. Further, while the car is accelerating in first gear, the ECU (Mechatronics unit) gives the command to turn on the second one in an even row.

Then, already at the moment of switching, the odd-numbered disk is disconnected and the even-numbered disk is switched on, while the next gear is similarly “prepared” for switching on in advance.

It turns out that if the car moves, for example, in 2nd gear and then picks up speed, at the command of the ECU, 3rd gear will also be almost completely engaged. As a result, when the moment of upshifting comes, the full shift from 2nd to 3rd takes a fraction of a second, the gears change very quickly, the power flow at the moment of shifting is practically not interrupted.

This feature of work is clearly reflected in the name of this type of gearbox, since a box with two clutches is usually called preselective (pre-selection and partial engagement of the next up or down gear). As a result, the DSG box provides high level comfort inherent in automatic transmissions and CVTs, as well as the dynamics and fuel efficiency of traditional mechanics.

Types of DSG boxes: DSG-6 and DSG-7

DSG boxes come in 6 and 7 speed. In this case, DSG 6 is "wet", while DSG 7 is "dry". The first option is designed for more torque and is put on powerful cars of the VAG concern. The DSG 7 version is installed on cars with less powerful internal combustion engines. The six-speed DSG 6 was developed first.

The clutch in such a box works in an oil bath. For this reason, this type of gearbox is called "wet". The disadvantages include the loss of power due to the large amount of oil and the need to implement its supply. The DSG7 version appeared later, has a "dry" clutch. At the same time, the reliability of this design has decreased, this type of gearbox has more problems and a shorter resource.

DSG resource and malfunctions of DSG boxes

Let's start with the problems. Most often, the problem is expressed in the form of shocks when shifting gears. The reason is too sharp engagement of the clutch, the car starts to twitch. Also, when shifting gears, bumps and rattles may occur. Another option may be the problem of losing traction on a car with DSG, and right in motion.

As a rule, such malfunctions are more inherent in DSG 7 with a dry clutch. Such a clutch is subject to rapid wear, in parallel, Mechatronics (ECU box) also gives certain failures.

In the list of other problems associated with this type of gearbox, wear of the shaft sleeve, problems with the clutch release fork, electrical problems (contacts, failure of sensors, etc.) should be highlighted. At the same time, it is important to understand that for a non-warranty car, DSG diagnostics and repairs are often expensive, and the cost of spare parts is also high.

As far as resources are concerned, it should be noted that initial stage there were no special problems with DSG 6 on average, up to 150-200 thousand km. However, after many VAG models began to massively install DSG 7, the number of calls during the warranty period on runs of 60-80 thousand km. increased noticeably.

As a result, the manufacturer launched a customer support program by extending the full warranty on the DSG 7 gearbox to 5 years or 150,000 km (whichever comes first). Within the framework of this program, all repair work (up to complete replacement unit) were performed free of charge.

Later, the program was curtailed, referring to the fact that VAG engineers finalized the software for the control unit, made certain changes to the clutch design, that is, they made the DSG 7 more reliable.

One way or another, taking into account the information provided, it is quite logical to assume that the average resource of DSG 6 is about 200 thousand km, while for DSG 7 this figure is about 150 thousand km.

As you can see, a serviceable DSG box is able to provide good acceleration dynamics, comfort and fuel efficiency. In other words, the main tasks set for the developers in the conditions of the fuel crisis and strict environmental regulations have been solved.

At the same time, the issue of resource and reliability was deliberately relegated to the background. In simple words, even the relatively reliable DSG 6 was quickly replaced by the DSG 7. At the same time, taking into account the obvious problems, VAG still preferred the expensive warranty repair program and the active dissemination of information about the DSG7 improvements in order to increase its reliability over the banal refusal of this gearbox.

In other words, instead of returning to the DSG 6 or the time-tested hydromechanical automatic, the manufacturer continues to install the DSG7 on many popular models of Volkswagen, Skoda, Audi, etc., claiming that the reliability of the box has increased significantly.

In practice, the feasibility of DSG is questioned by many experienced motorists. And if we are talking about DSG 6, real mileage does not exceed 100 thousand km. and the gearbox is working properly, then such a car can still be considered for purchase.

As for the DSG7, especially the first years of production, even if such a gearbox works fine, this does not mean that the residual resource is still large enough. In other words, you need to immediately prepare for the repair of the gearbox, and the costly one.

We add that although there is nothing special to break in the box itself (shafts, gears and other elements “walk” for a long time), problems may arise with the clutch assembly, sensors, actuators, electronic control unit, wiring and a number of other mechanisms, parts and assemblies .

At the same time, in some cases, it may be enough to flash the ECU and replace the clutch, while in others it is necessary to change expensive and officially non-repairable components.

Finally, we note that another minus DSG, especially DSG7 is their low liquidity in the secondary market. This means that such a car, especially a premium model with low mileage, can be bought expensively, but then it will not be possible to sell it profitably.

Simply put, most motorists today are well aware of the problems of this box and simply do not consider cars with the specified type of gearbox. Another option may be to try to significantly reduce the cost of a used car with DSG during the auction. The reason is quite obvious, since the potential buyer separately takes into account the cost of a possible repair of the preselective robot, and such repairs may be required very soon.

Operating rules

In order for the box to live for a long time, you should familiarize yourself with the rules for its operation, read the instructions and understand how it works. Here are some tips:

For correct operation warm up the transmission before driving;
It is important to avoid any slippage and aggressive driving;
Overcome dense congestion in the S position without switching to neutral;
Oil should be changed every 50,000;
For a "dry" clutch, it is better to shift into neutral during long stops.

If you ignore the careful attitude to this mechanism, then problems will soon arise with it and expensive repairs will be needed.

Change of oil

Volkswagen writes that an oil change at these gearboxes is only necessary during repairs - the oil is filled for the entire service life, it is not recommended to change it while the car is in operation. If the gearbox has been repaired, then an oil change is necessary every 60,000 kilometers. Service station specialists who have already dealt with the repair of these gearboxes claim that in any case, an oil change is necessary every 50,000 kilometers, otherwise no one guarantees that the box will last a long time.

The DSG 0B5 has two lubrication systems (gearbox housing and mechatronics). The mechatronics unit has a different oil, designed specifically for 0B5. Under no circumstances should such oil be drained from mechatronics. Modification 0B5 was installed on the Audi A4, from where it migrated further to models A and Q.

If the oil change is done by hand, then another nuance awaits the motorist. There is no filler hole, a suitable hole can only be found under the battery. All problems are solvable if you know what to do.

Oil for replacement is suitable G52512A2, you need to fill in 1.7 liters (5.5 for a complete replacement). An oil change can be cheaper if you use an analogue of SWAG 10 92 1829.

In general, changing the oil is no different from a similar procedure for an automatic transmission.

Can a car with a gearbox be towed by a robot?

It is not recommended to tow a car with a DSG box. The box may fail from the transportation procedure itself, and in this case the warranty will not apply. The official service station may refuse to repair due to violation of operating conditions. It is advisable to call a tow truck. If this is not possible and the vehicle must still be towed, the following should be done.

Turn on the ignition;
Shift the gearbox to neutral (towing at speed is not recommended and may damage the gearbox).

Towing is allowed for a distance of not more than 50 kilometers at a speed of not more than 50 km / h.

The opposite situation, when another car needs to be towed by a car with a robot box, is also not safe. In extreme cases, it is necessary to transfer the box to manual mode and move only in first gear and it is better not to exceed the speed of 30 km / h.

Tow truck for transporting cars

DSG adaptation

Adaptation is a procedure for adjusting the operation of the gearbox and the mechatronics unit, which is necessary after repair and in some cases when the box does not work correctly. The procedure is simple and you can do it yourself. Usually adaptation is carried out through Vag Com. Vag Com is a diagnostic program that will allow you to "make friends" with a computer, diagnose and configure some systems. The program has a simple and intuitive interface, it takes up little disk space and it has its advantages compared to analogues. In order for the adaptation to be carried out correctly, follow the following algorithm:

- Box in position P and warmed up to 30-100 degrees C;

— The engine is started;

— The brake pedal is depressed for the duration of the entire procedure.

If all conditions are met, you must connect Vag Com. The adaptation is done as follows:

In the program interface we find the item Basic automatic transmission settings.
Select the Gear Clutch Settings item, press “Go!”. The box will begin to make sounds, and the numbers in the program will change. You have to wait until it stops.
Select the Gear Shift Points item, click Go. Similar to point 2, we are waiting.
We select the item Clutch adaptation, the actions are similar to point 2. Then we do everything similarly to point 2.
Item Basic settings.
Item Pressure adaptation.
Item With shift paddles installed.
Item ESP and Cruise.
Click Done.
We turn off the ignition.
We wait a few seconds.
We turn on the ignition.
We look for errors, if necessary, delete them.
Exit the controller.
Without using cruise control, we perform a test drive.
Get off their Vag Com. Adaptation completed.

Replacing the mechatronics unit will require a new firmware. Fortunately, this is easy to do. DSG 6 mechatronics and DSG 7 mechatronics control units are easily flashed using this program.

We repair DSG

If there are jerks and kicks during the operation of the box, extraneous noise, then it's time to go for diagnostics. DSG repair is quite complicated

Double clutch on robotic boxes gear shifting, despite all its advantages, is a consumable item. No matter "wet" type of clutch or "dry". With aggressive use, dual clutches hardly live up to 40,000, it is better to change it as an assembly at the first symptoms.

The mechatronics unit is very delicate, requiring careful handling, warming up and not loving overheating. One of its weak points is the cooling system pipes made of plastic. From temperature changes and vibration, they can burst or crack, which will lead to coolant leaks and overheating of the box. Moreover, the gearbox can overheat from prolonged standing at a traffic light at speed.

The heat exchanger unit can generally depressurize and mix oils with antifreeze.

The roller bearings of the output shafts can run less than 50,000 if they have been subjected to heavy loads. When a gear tooth breaks, a characteristic knock will appear, which is also not uncommon. Also, extraneous noise in the box may indicate wear on the input shaft bearing, other bearings of the mechanical part, and the box differential. When the engine speed increases, stops, turns, the noise usually increases.

Failure of the electric pump of the control unit will immobilize the machine. If some electrical circuit in it is sour, this behavior may be periodic. A faulty control unit can periodically throw the box into emergency mode.

Worn solenoids can lead to jerky gear changes, the self-diagnostic system will not see problems. If you do not pay attention to such signs, then, most likely, soon the box will completely “stand up”. Its repair is not cheap, and in Russia it has not yet been mastered very well. It can even be difficult to find a suitable service with specialists who will undertake such work. Before buying a car with a robot, consider whether all its advantages are worth such repair problems.

The DSG box, like all similar boxes, is a fairly early development and they are just beginning to be modernized and worked out. The manufacturer's warranty still covers all possible troubles. Until the moment when eternal robot boxes appear, as the American and Japanese millionaire automatic transmissions once appeared, it will be a long time, maybe another 2-3 generations of these gearboxes.

Spare parts

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